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Delegates are invited to meet and discuss with the poster presenters in this topic directly after the session 'Advanced operation & maintenance' taking place on Thursday, 13 March 2014 at 11:15-12:45. The meet-the-authors will take place in the poster area.

Yoshinori Ueda The Japan Wind Energy Association, Japan
Co-authors:
Takao Maeda (2) F Yoshinori Ueda (3) P Toru Nakao (4) Katsuhiko Shono (5) Takahiro Ishiyama (5)
(1) Mie University, Tsu, Japan (2) The Japan Wind Energy Association, Tokyo, Japan (3) The Japan Wind Power Association, Tokyo, Japan (4) The Japan Society of Industrial Machinery Manufacturers, Tokyo, Japan (5) The Japan Electrical Manufacturers’ Association, Tokyo, Japan

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Presenter's biography

Biographies are supplied directly by presenters at EWEA 2014 and are published here unedited

Yoshinori Ueda is the director of the Japan Wind Energy Association (JWEA), the leader of the International Committee of both the Japan Wind Power Association (JWPA) and the JWEA, the leader of the GWEC Japan Committee, the chairman of the Wind Power System Technical Committee of the Japan Electrical Manufacturers' Association (JEMA) and the branch leader of the Wind Power Committee in the New Energy Foundation (NEF). He majored mechanical engineering in the Kyoto University and he has been working for the power plant production in the Mitsubishi Heavy Industries, Ltd.(MHI) for more than 30 years.

Abstract

Japanese wind turbine industry, research result of production statistics

Introduction

Japanese Wind Turbine industry began to collect production statistics of wind turbines and their components made in Japan under the guidance of Japanese Ministry of Economy, Trade and Industry since 2010. This research results are very useful to understand the wind turbine industry in Japan. The Japan Society of Industrial Machinery Manufacturers (JSIM) acts secretary work and publishes the annual research report. The Japan Electrical Manufacturers’ Association (JEMA), the Japan Wind Power Association (JWPA) and the Japan Wind Energy Association (JWEA) support this research. Prof. Takao Maeda in Mie University is the chairman of the research committee.

Approach

We organized the Japanese Wind Turbine Industry Production Statistics Study Committee in June 2010. 7 industrial societies and 17 companies have joined the committee and more 30 companies had cooperation to the discussion. These members include the manufactures of wind turbines, blades, generators, power converters, bearings, towers and so on. Prof. Takao Maeda in Mie University became the chairman, and the Japan Society of Industrial Machinery Manufacturers (JSIM) took secretary work.
At first, we classify the wind turbine industry into the 17 categories as wind turbines themselves, their main components and associated facilities. Then, we nominated more than 400 companies which make wind turbine components now or in future. These works have conducted by the core members of the committee and the secretary of the JSIM and the JEMA and have finished by September 2010. We also made interview with main player of Japanese wind turbine industry, like Mitsubishi Heavy Industries Ltd., Japan Steel Works Co. and Hitachi Co.. We send the questionnaire sheet regarding production statistics of 2009 fiscal year and business plan to the nominated 400 companies in October with the name of Japanese METI and we got the answer by December. Around 100 to 200 companies answered our questionnaire sheet every year. We repeat above procedure every year since 2010. Therefore, our statistic is published about 1 year later.
The secretary gathered the production statistics data, made basic tables and charts. The categorization was re-arranged to include more than 3 companies so as not to detect each companies sales data. These data are presented to the committee and discussed by the committee members for several times. The production statistics and the analyzed results are summarized as the annual report. The report was published from the JSIM every spring for 3 years from 2011. We added 3 years trend analysis for our latest report published in 2013.


Main body of abstract

1. Wind Turbines
We classify it to 4 categories by rated output, “Micro WTG” as “Lesser than 1kW”, “Small WTG” as “from 1kW to 50kW”, “Medium WTG” as “from 50kW to 1MW” and “Large WTG” as “More than 1MW”. There are 18 companies manufacturing wind turbines in Japan and 1200 employee are working directory for wind turbine manufacturing. 4 companies are manufacturing “large WTG”. The total sales in 2011 fiscal year are 76 billion JPY. “Large WTG” has more than 99% of the sales. 66 billion JPY (87% of total sales) of wind turbines are exported to abroad. 51 billion JPY (68% of total sales) is used for purchasing components and materials. 25 billion JPY (49% of purchasing) is purchased from domestic Japanese suppliers.
2. Generators
There are 7 companies and 6 factories producing generators and 271 employee are working directory for this production. The total sales in 2011 fiscal year are 6.1 billion JPY. Almost all generators are exported. 3.7 billion JPY (60%) of generator sales is used for purchasing equipment and materials. 3.1 billion JPY (85% of purchasing) is purchased from domestic Japanese suppliers. Hitachi Co. and Yasukawa Electric Co. intend to get large share in the world market. They have enough ability based on the fossil power generation business.
3. Controllers
There are 11 companies and 9 factories producing controllers and 346 employee are working directory for this production. The total sales in 2011 fiscal year are 1.6 billion JPY. 66% of controllers are exported. 0.36 billion JPY (22%) of controller sales is used for purchasing equipment and materials. 0.25 billion JPY (69% of purchasing) is purchased from domestic Japanese suppliers.
4. Main Bearings
There are 3 companies and 5 factories producing wind turbine main bearings and 800 employee are working directory for this production. The total sales in 2011 fiscal year are 14.2 billion JPY. 13.6 billion JPY (96%) of bearings are exported. 1.65 billion JPY (12%) of bearing sales is used for purchasing equipment and materials. Almost all of them are purchased from domestic Japanese suppliers. JTEKT, NSK and NTN are very competitive in this business, because they have enough and long experience from automobile business.
5. Gearboxes
There are 3 companies and 5 factories producing gearboxes and 215 employee are working directory for this production. The total sales in 2011 fiscal year are 4.8 billion JPY. 3.9 billion JPY (81%) of gearboxes are exported. 1.83 billion JPY (38%) of gearbox sales is used for purchasing equipment and materials. 0.95 billion JPY (52% of purchasing) is purchased from domestic Japanese suppliers. Japanese manufacturers are very good at precise machinery. Their products are trustworthy.
6. Blades and nacelle FRP cover
There are 4 companies and 5 factories producing wind turbine blades and 343 employee are working directory in Japan for this production. The total sales in 2011 fiscal year are 0.04 billion JPY for domestic production and 15.5 billion JPY for abroad production by Japanese companies. Blade manufacturing is labor-intensive industry. Therefore, it is very difficult to keep profitability in Japan where the labor cost is very high.
7. Towers and auxiliaries
There are 11 companies and 5 factories producing towers and their auxiliaries and 235 employee are working directory for this production. The total sales in 2011 fiscal year are 1.14 billion JPY for domestic production and 1.5 billion JPY for abroad production by Japanese companies. Tower manufacturing is also labor-intensive industry. Therefore, it is very difficult to keep profitability in Japan where the labor cost is very high.


Conclusion

There are 57 companies in charge of manufacturing wind turbines and their components. About 2,300 people are directly working for wind turbine industry in Japan among the total employee of these companies are 510 thousand people. The total sales of wind turbines and their components made in Japan is 112 billion JPY for 2011 fiscal year. 96 billion JPY are exported to foreign countries. Most of them are large wind turbines exported to the U.S.A. 28 billion JPY are used for importing components and materials from abroad, this is about 25% of total sales. The oversea production of Japanese companies is 17 billion JPY. Sales of general-purpose products, such as power converters (inverter, converter, trans, etc.) cannot be caught by our research. Their manufacturers don’t categorize and gather their sales data for “wind turbine use”, therefore, they cannot answer our questionnaire sheet sufficiently. We suspect sales and employee to increase if general-purpose products are included.
Japanese wind turbine manufacturers have small share in the world. On the other hand, Japanese component supplier have more large market share in the world at large bearings, generators and gearboxes, because Japanese companies are very good at precise machinery and high technology electric equipment.
The sales of Japanese wind turbine industries are decreasing for this 3 years due to the world depression after the “Lehman Shock”. The total sales are 251 billion JPY in 2009 fiscal year, 154 billion JPY (-39%) in 2010 fiscal year and 112 billion JPY (-27%) in 2011 fiscal year. It will increase when Japanese domestic market grows up by Feed in Tariff introduced in July 2012. For the domestic market forecast, about 50% of companies answered “It will expand clearly" and about 30% of companies answered “It will expand somewhat”. About 80% of Japanese companies have positive forecast for future Japanese domestic market.



Learning objectives
The Japanese government has chosen renewable energy industry as the “Strategic growth areas”. We want to contribute to achieve this political target by giving sufficient information in our research results.


References
Research report of Wind Turbines & their Components Industry in Japan, by the Japan Society of Industrial Machinery Manufacturers (JSIM), published in May 2013 (in Japanese)
Research report of Wind Turbines & their Components Industry in Japan, by the Japan Society of Industrial Machinery Manufacturers (JSIM), published in April 2012 (in Japanese)
Research report of Wind Turbines & their Components Industry in Japan, by the Japan Society for the Promotion of Machine Industry (JSK), published in March 2011 (in Japanese)